M 6B 8B 9.8B
OWNER’S
MANUAL
M 6B
8B
9.8B
OB No.003-11029-D
! READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.
Copyright © 2011 Tohatsu Corporation. All rights reserved. No part of this manual may
be reproduced or transmitted in any from or by any means without the express written
permission of Tohatsu Corporation.
YOUR TOHATSU OUTBOARD MOTOR
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY CARD is correctly and
completely filled out and mailed to the addressee noted there on. This WARRANTY
CARD identifies you as the legal owner of the product and serves as your warranty
registration.
TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR
WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS
PROCEDURE IS NOT FOLLOWED.
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before
you take delivery.
Limited Warranty
Please refer to the TOHATSU outboard motor Limited warranty provided to you with
this product, the terms and conditions of which, as amended from time to time, are
incorporated by reference into the manual.
Serial Number
In the space below, please record the outboard motor's serial number (indicated both
on the bottom cowl and on the cylinder block). The serial number will be needed in the
event of theft or to quickly identifying the outboard motor type.
Serial Number :
To You, Our Customer
Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of
an excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance
procedures described later in this manual should be followed carefully. Should a
problem arise with the outboard motor, please follow the troubleshooting procedures
listed at the end of this manual. If the problem persists, contact an authorized
TOHATSU service shop or dealer.
We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
CONTENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
NAMES OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. Installing the remote control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. Installing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1. Recommended gasoline types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2. Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1. Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3. Forward and reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4. Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6. Tilt up, tilt down and shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVING AND CARRYING THE OUTBOARD MOTOR . . . . . . . . . . . . . . . . 38
1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3. Storing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TRAILERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2. Remote control lever load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3. Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1. Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2. Periodic inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5. Motor submerged in water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7. Checking after striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OPTIONAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7
INDEX
GENERAL SAFETY INFORMATION
1. SPECIFICATIONS
1
2. NAMES OF PARTS
2
3. INSTALLATION
3
4.PRE-OPERATING PREPARATIONS
4
5.ENGINE OPERATION
5
6.REMOVING AND CARRYING THE OUTBOARD MOTOR
6
7.TRAILERING
7
8.ADJUSTMENT
8
9.INSPECTION AND MAINTENANCE
9
10.TROUBLESHOOTING
10
11.TOOL KIT AND SPARE PARTS
11
12.OPTIONAL ACCESSORIES
12
13.PROPELLER TABLE
13
8
GENERAL SAFETY INFORMATION
NOTICE : DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure
to thoroughly read and understand this Owner's Manual and carefully follow all of
the instructions. Of particular importance is information preceded by the words
"DANGER," "WARNING," "CAUTION," and "Note." Always pay special attention to
such information to ensure safe operation of the outboard motor at all times.
!
������
Failure to observe will result in severe personal injury or death, and possibly property damage.
!
�������
Failure to observe could result in severe personal injury or death, or property damage.
!
�������
Failure to observe could result in personal injury or property damage.
Note
This instruction provides special information to facilitate the use or maintenance of the
outboard motor or to clarify important points.
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch tether
is pulled off. This stop switch tether can be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls
overboard.
We highly recommend use of the Emergency Stop Switch tether.
!
�������
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out
in heavy seas) could cause passengers to lose their balance and even fall overboard,
or it could result in loss of power in heavy seas, strong currents, or high winds. Loss of
control while mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.)
stop switch tether is coiled and can extended to a full 1,300 mm (51 inch.).
9
SAFE OPERATION OF BOAT
As the operator/driver of the boat, you are responsible for the safety of those aboard
and those in other boat around yours, and for following local boating regulations. You
should be thoroughly knowledgeable on how to correctly operate the boat, outboard
motor, and accessories. To learn about the correct operation and maintenance of the
outboard motor, please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action
should he or she see a power boat heading in his /her direction, even at a slow speed.
Therefore, when your boat is in the immediate vicinity of people in the water, the
outboard motor should be shifted to neutral and shut off.
!
�������
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH
A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY
ATTACHED TO A BOAT OR GEAR HOUSING.
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance
on this outboard motor. Be sure to use genuine parts, genuine lubricants, or
recommended lubricants.
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct
maintenance procedures. It is the operator's responsibility to perform all safety checks
and to ensure that all lubrication and maintenance instructions are complied with
for safe operation. Please comply with all instructions concerning lubrication and
maintenance. You should take the engine to an authorized dealer or service shop for
periodic inspection at the prescribed intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce the
chance of problems and limit overall operating expenses.
MOUNTING
Outboard motor mounting must be performed by trained service person(s) using lift or
hoist with sufficient capacity.
10
SPECIFICATIONS
6B MF, 8B MF, 8B EF, 8B EP, 9.8B MF, 9.8B EF, 9.8B EP
MODEL
1
Item
6B MF
8B MF
8B EF
8B EP 9.8B MF 9.8B EF 9.8B EP
Overall Length
mm (in)
793 (31.2)
505 (19.9)
793 (31.2)
505 (19.9)
Overall Width
mm (in)
320 (12.6)
275 (10.8)
320 (12.6)
275 (10.8)
S mm (in)
996 (39.2)
L mm (in)
1,123 (44.2)
UL mm (in))
1,250 (49.2)
Overall
Height
S mm (in)
435 (17.2)
L mm (in)
562 (22.2)
UL mm (in))
689 (27.1)
Transom
Height
S kg (lb)
26 (57)
29 (64)
28.5 (63)
26 (57)
29 (64)
28.5 (63)
L kg (lb)
27 (60)
30 (66)
29.5 (65)
27 (60)
30 (66)
29.5 (65)
UL kg (lb)
28 (62)
31 (68)
30.5 (67)
28 (62)
31 (68)
30.5 (67)
Weight
Output
kW (Hp)
4.4 (6)
5.9 (8)
4,500 – 5,500
Max. Operating Range rpm
Idle
Speed
7.2 (9.8)
5,000 – 6,000
Forward Gear rpm
750
Neutral Gear rpm
950
2
Number of Cylinder
Piston Displacement
mL (Cu in)
Bore x Stroke
169 (10.3)
50 x 43 (1.97 x 1.69)
mm (in)
Through hub exhaust
Exhaust System
Engine Oil Mixed Gasoline
Lubrication System
Forced water cooling
Cooling System
Starting System
Ignition System
Manual
Electric starter motor*
BP7HS-10 or BPR7HS-10
6
Trim Position
Gear Oil
Electric starter motor*
Flywheel Magneto C.D. Ignition
Spark Plug
Fuel Mixing Ratio
Manual
Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 320mL
Fuel Tank Capacity
L (US gal)
Gear Reduction Ratio
* : with manual
Remark : Specifications subject to change without notice.
12 (3.17)
2.08 (13 : 27)
NAMES OF PARTS 11
NAMES OF PARTS
6B MF, 8B MF, 9.8B MF
1
a
q
w
s
p
2
3
2
e
r
4
t
5
y
6
7
u
8
9
i
o
0
d
g
h
j
f
k
1 Tilt Handle
q Starter Handle
a Choke Knob
2 Top Cowl
w Shift Lever
s Fuel Connector
3 Bottom Cowl
e Throttle Grip
d Primer Bulb
4 Cooling Water Check Port
r Clamp Screw
f Fuel Tank
5 Tilt Stopper
t Clamp Bracket
g Fuel Tank Cap
6 Drive Shaft Housing
y Thrust Rod
h Air Vent Screw
7 Water Plug
u Oil Plug (Upper)
j Fuel Connector
8 Anti Ventilation Plate
i Water Inlet
k Fuel Pick up Elbow
9 Anode / Trim Tab
o Oil Plug (Lower)
0 Propeller
p Stop Switch
12 NAMES OF PARTS
8B EF, 9.8B EF
1
q
p
s
w
a
d
2
2
3
e
r
4
t
5
y
6
7
u
8
9
i
f
o
0
g
j
k
l
h
;
1 Tilt Handle
q Starter Handle
a Stop Switch
2 Top Cowl
w Shift Lever
s Main Switch
3 Bottom Cowl
e Throttle Grip
d Fuel Connector
4 Cooling Water Check Port
r Clamp Screw
f Battery Cord
5 Tilt Stopper
t Clamp Bracket
g Primer Bulb
6 Drive Shaft Housing
y Thrust Rod
h Fuel Tank
7 Water Plug
u Oil Plug (Upper)
j Fuel Tank Cap
8 Anti Ventilation Plate
i Water Inlet
k Air Vent Screw
9 Anode / Trim Tab
o Oil Plug (Lower)
l Fuel Connector
0 Propeller
p Choke Knob
; Fuel Pick up Elbow
NAMES OF PARTS 13
8B EP, 9.8B EP
1
q
w
p
o
2
2
3
e
4
r
5
t
6
7
y
8
9
u
a
i
0
s
f
g
k
l
;
z
h
d
j
1 Tilt Handle
q Starter Handle
2 Top Cowl
w Shift Lever
3 Bottom Cowl
e Clamp Screw
4 Cooling Water Check Port
r Clamp Bracket
5 Tilt Stopper
t Thrust Rod
6 Drive Shaft Housing
y Oil Plug (Upper)
7 Water Plug
u Water Inlet
8 Anti Ventilation Plate
i Oil Plug (Lower)
9 Anode / Trim Tab
o Choke Knob
0 Propeller
p Fuel Connector
a Battery Cord
s Primer Bulb
d Fuel Tank
f Fuel Tank Cap
g Air Vent Screw
h Fuel Connector
j Fuel Pick up Elbow
k Remote Control
l Main Switch
; Stop Switch
z Cord Assembly
14
INSTALLATION
1. Mounting the outboard motor on boat
!
3
�������
Most boats are rated and certified
in terms of their maximum allowable
horsepower, as shown on the boat’
s certification plate. Do not equip your
boat with an outboard motor that
exceeds this limit. If in doubt, contact
your dealer.
Do not operate the outboard motor until
it has been securely mounted on the
boat in accordance with the instructions
below.
Transom matching
1 Be sure that the anti ventilation plate
of the outboard motor is 30-50mm
(1.2-2 in) below the bottom of hull.
If the above condition cannot be
met due to the shape of the bottom
of your boat, please consult your
authorized dealer.
Bottom of hull
30-50 mm
(1.2-2 in)
Anti Ventilation Plate
Installation
■ Single-engine Installation
Set engine at center of boat.
Center of Boat
2 To attach the outboard motor to the
boat, tighten the clamp screws by
turning their handles.
Also, use the bolts to secure
the outboard motor brackets on
transom board.
Boat Transom
Secure the outboard motor with a
rope to prevent loss overboard.
Note
A rope is not included in the standard
accessories.
Clamp screw
INSTALLATION 15
!
�������
• Before beginning the running test,
check that the boat with maximum
capacity loading floats on the
water in a proper attitude. Check
the position of water surface on
the driveshaft housing. If the water
surface is near the bottom cowling,
in high waves, water may enter the
engine cylinders.
• Incorrect outboard motor mounting
height or existence of underwater
object(s), such as hull bottom
design, bottom surface conditions
or underwater accessories,
can cause water spray possibly
reaching the engine through an
opening of the bottom cowling
during cruising. Exposing the
engine to such conditions for
extended periods can lead to
severe engine damage.
!
�������
Mounting bolts should be installed with
the bolt head at inside surface of the
transom. Mounting bolts installed with
the threaded end at the inside surface
of the transom can cause personal
injury.
Notes
1. Apply sealing agent, such as
silicone sealed between the bolts
and the transom board holes before
tightening the bolts.
2. Be sure to tighten the mounting bolt
nuts to the specified torque.
(30 Nm (3.0kgf)13ft · lb)
!
�������
• Mounting the outboard motor without
following this manual can lead to
unsafe conditions such as poor
maneuverability, lack of control or
fire.
• Loose clamp screws and/or mounting
bolts can lead to the release or
displacement of the outboard motor,
possibly resulting in lost of control and/
or serious personal injury. Be sure that
fasteners are tightened to the specified
torque (30 Nm (3.0kgf) 13ft·lb). Check
the fasteners for tightness from time to
time.
• Be sure to use outboard mounting
fasteners included in the outboard
motor package or their equivalents
in terms of size, material, quality and
strength.
Tighten fasteners to the specified
torque (30 Nm (3.0kgf) 13ft·lb). Test
cruise to check if fasteners are
tightened securely.
• Outboard motor mounting must
be performed by trained service
person(s) using lift or hoist with
sufficient capacity.
3
16 INSTALLATION
2. Installing the remote control devices
It is recommended that you consult
with your authorized dealer for
installation adjustment of the remote
control device.
■
3
■
■
Installation of the Remote Control
Cables (Box side) :
Fo l l o w t h e i n s t r u c t i o n m a n u a l
provided with the remote control.
Installation of the Remote Control
on your boat :
Fo l l o w t h e i n s t r u c t i o n m a n u a l
provided with the remote control.
Installation of the Remote Control
Cable (engine side) and the Cord
Assembly (Wiring Harness) :
1 Fitting of holder cap and sleeve B
guide
Throttle side......Fit the holder cap
to the end of the cable and fix it
by the nut.
Holder
cap
Ball
holder
Spring
Washer
Nut
Cable outer
groove
Throttle cable
Shift side......Fit the sleeve B guide
to the end of the cable and fix it
by the nut.
Sleeve B guide
Lock pin
Nut
Spring
Spring pin
Cable outer
groove
Shift cable
2 Fitting of Remote Control Cable to
Engine
Throttle side......Set the throttle
cable to the cable clip and then
connect the holder cap to the ball
joint of throttle lever.
Shift side......Set the shift cable to
the cable clip and then insert the
lock pin at the shift lever fitting
hole and turn it 90° to lock it.
INSTALLATION 17
Sleeve B gulde:
fit it to remove
control cable and
flt it to shift lever
Holder Cap:
fit it to remove
control cable and
flt it to ball joint
Shlft cable
Throttle lever
To C.D. unlt
Cable outer groove
Shlft Lever
3
Cable
clip
Steerfng
Hook plate
Connect it
to lead wlre
of remote
controf box
Note
Note
Put the control lever in the Neutral
position and the free accel lever in the
fully closed position.
Note
Length of Remote Control Cable
depends on a size of a boat.
!
Remote control stop cord
(excluded from fining pans)
�������
Be careful not to loop remote control
cables to diameter of 406 mm (16
inches) or less.
Confirm whether the engine side shift
is in gear when shifting the control
lever of the remote control to its first
position in Forward or Reverse (about
32°) and whether the throttle of the
carburetor is fully open when shifting
the lever further.
Confirm whether the carburetor’s
throttle is fully closed when the control
lever is shifted to the Neutral position.
If it is not, adjust the position of the ball
holder.
18 INSTALLATION
3 Connecting the Cord Assembly (Wiring Harness)
Pass the cord assembly from the remote control through the hole in the bottom
cowl and connect the electric terminals and then clamp the cord assembly
according to the drawing below.
3
Rectifier
Fuse wire
Choke
solenoid
Clamp
R
B
Blue
R
G
Starter
solenoid
B
G
G
Air silencer
Blue
Clamp
B
Clamp
Cord assembly
Single remote
Control box
(RC 5C)
Battery Cord
!
�������
Do not disconnect the cord assembly
when the outboard motor is in
operation or you will lose control of the
outboard motor.
INSTALLATION 19
3. Installing the battery
1 Place the battery box in a convenient
position away from possible water
spray. Securely fasten both the box
and the battery so they do not shake
loose.
Note
Minimum recommended battery :
12V, 40AH (465 Marine Cranking
Amps (MCA) or 350 Cold Cranking
Amps (CCA)) Specifications and
features of batteries vary among
the manufacturers. Consult the
manufacturer for details.
!
�������
Battery electrolyte contains sulfuric
acid and thus is hazardous, causing
a burn if it comes in contact with your
skin, or poisonous if swallowed.
KEEP BATTERY AND ELECTROLYTE
AWAY FROM REACH OF CHILDREN
When handling the battery, be sure to:
• Read all warnings shown on the
battery case
• Prevent electrolyte from coming in
contact with any part of your body.
Contact can cause serious burn or,
if it comes in contact with your eye,
loss of sight. Use safety glasses
and rubber gloves.
In case battery electrolyte comes in
contact with:
• Skin, flush thoroughly with water.
• Eye, flush thoroughly with water,
and then seek immediate medical
treatment.
In case battery electrolyte is
swallowed:
• Seek immediate medical treatment.
!
�������
Battery generates explosive hydrogen
gas. Be sure to:
• Charge the battery in a wellventilated place.
• Place the battery away from any
source of fire, sparks and open
flames such as burners or welding
equipment.
• Do not smoke when handling the
battery.
• Do not smoke near the battery when
the battery is charging.
!
�������
• Make sure that the battery cords do
not get stuck between the outboard
motor and boat when turning, etc.
• The starter motor may fail to
operate if the cords are incorrectly
connected.
• Be sure to correctly connect the (+)
and (−) cords. If not, the charging
system will be damaged.
• Do not disconnect the battery
cords from battery while the engine
is operating, the electrical parts
could be damaged.
• Always use a fully charged battery.
!
�������
Do not use a battery that is not
recommended. Use of a battery
not recommended can lead to poor
performance of, and/or damage to, the
electrical system.
3
20 INSTALLATION
2 Connect the positive lead (+) to the
positive terminal (+) of the battery,
and then connect the negative lead
(−). When disconnecting the battery
always remove the negative lead (−)
first. After connecting the positive
terminal (+), securely place a cap on
it to prevent short circuits.
3
Battery cable
(red)
Battery cable
(black)
21
PRE-OPERATING PREPARATIONS
!
������
Consult an authorized dealer for details
on handling of gasoline, if necessary.
Gasoline and its vapors are very
flammable and can be explosive.
When carrying a fuel tank containing
gasoline:
• Close the air vent screw of fuel tank
cap, or gasoline vapor will be emitted
through the air vent screw, creating a
fire hazard.
• Do not smoke.
When or before refueling :
• Stop the engine, and do not start the
engine during refueling.
• Do not smoke.
• Be careful not to overfill fuel tank. Wipe
up any spilled gasoline immediately.
When or before cleaning the gasoline tank :
• Dismount fuel tank from the boat.
• Place the fuel tank away from every
source of ignition, such as sparks or
open flames.
• Do the work outdoors or in well
ventilated area.
• Wipe up any spilled gasoline
immediately.
After cleaning gasoline tank :
• Wipe up any spilled gasoline
immediately.
• If the fuel tank is disassembled for
cleaning, reassemble carefully. Imperfect
assembly may cause a fuel leak, possibly
leading to fire or explosion.
• Dispose of aged or contaminated
gasoline in accordance with local
regulations.
1. Recommended gasoline types
!
�������
Use of low-quality gasoline results in
a short engine life as well as starting
difficulties and other engine problems.
We recommend use for Fuel stabilizer.
Use of unleaded gasoline
Use a major brand of automotive
unleaded gasoline with a minimum
pos ted oc tane r a ting o f 91RON.
Automotive gasoline that contain fuel
injector cleaner are preferred for added
internal engine cleanliness. Leaded
gasoline is acceptable in areas where
unleaded gasoline is not available.ere
unleaded gasoline is not available.
4
22 PRE-OPERATING PREPARATIONS
Use of alcohol free gasoline
!
�������
Use of gasoline containing alcohol can
cause engine starting and/or operating
difficulties, wear of and damages to
engine parts, and deterioration of
chemical parts, which may lead to
shortening of your outboard motor’s life.
Note
4
The adverse effect caused by the alcohol
content is more severe with methanol than
with ethanol.
TOHATSU recommend the use of
gasoline if its ethanol content is less
than 10% or methanol content is less
than 5%, only in case alcohol free
gasoline is not available.
The alcohol component of the gasoline
absorbs moisture from the air, which
may disturb regular fuel flow in the fuel
system, and also accelerate rusting of
engine parts.
Mixing of the moisture in the engine oil
can also deteriorate the properties of
the lubricant.
If the use of gasoline containing alcohol
is inevitable, or presence of alcohol is
suspected in the gasoline, it is strongly
recommended to add a filter that has
water separating capability, and check
the fuel system for leaks and mechanical
parts for corrosion and abnormal wear
more frequently.
And, in case any of such abnormality
is found, discontinue the use of such
ga s oline a nd c on t a c t our de a le r
immediately.
Damages resulting from the use of
gasolines that contain alcohol are not
covered under the limited warranty.
Fuel tank capacity : 12 liters (3.17 U.S. gal)
Fuel Tank : When using a fixed fuel
tank in place of genuine fuel tank, it is
recommended to select a one with a
structure facilitating interior cleaning.
!
�������
Do not fill the fuel tank over capacity. The
rise of gasoline temperature may cause
gasoline to expand which, if overfilled, may
leak through air vent screw when it is open.
Leaking gasoline is a dangerous fire hazard.
PRE-OPERATING PREPARATIONS 23
Note
2. Recommended engine oil
Use of engine oils that do not meet
these requirements will result in reduced
engine life, and other engine problems.
Use a genuine engine oil or
recommended one. Refer to your
Distributor.
Will not recommend use of other two
stroke engine oil.
Add engine oil into fuel oil tank. The
mixing ratio with gasoline is 1 : 50 (one
part oil and 50 parts gasoline). Mix well
by hand. The mixing ratio during breakin running is 1 : 25.
�������
!
Do not mix different brands of oil.
Mixing different brands of oil, or
different types of oil even if the brand is
the same, may cause gelling, resulting
in possible filter screen blockage.
This could result in serious engine
damage because of impaired lubrication
performance.
Engine Oil : Gasoline
During break-in
1 : 25
After break-in
1 : 50
Fuel by Oil Mixing (1:25, 1: 50)
Oil
1.2L
1.1L
1.0L
0.9L
0.8L
0.7L
0.6L
0.5L
0.4L
0.3L
0.2L
0.1L
0
Mixing Ratio
(0.96: 24)
1: 25
(0.48:12)
(0.48:24)
1: 50
(0.24:12)
2L
12L
24L
Gasoline
30L
4
24 PRE-OPERATING PREPARATIONS
Engine oil – gasoline mixing
procedure
For quantities of engine oil and gasoline
to be pre-mixed, refer to table in
previous page.
!
4
�������
● Do not use other than two stroke
engine oil with specified grade, or
the engine may be damaged.
● Do not use fuel prepared in other
than specified mixing ratio.
- Lack of engine oil can cause
severe engine trouble such as
piston seizure.
- Excess of engine oil can shorten
spark plug life, and/or cause
increase of noxious exhaust.
■ When portable fuel tank is used for
operation of outboard motor(s):
1 Pour engine oil into fuel tank, and
then, gasoline.
2 Put cap on the tank, and close
tightly.
3 Close air vent plug tightly.
!
�������
Loose cap or air vent plug can cause leak
of fuel during shaking the tank.
4 Shake the tank to mix engine oil
and gasoline well and even.
■ When fuel tank built in the boat
is used for operation of outboard
motor(s):
1 Prepare separate fuel container
for pre-mixing.
2 Pour engine oil into fuel container,
and then, gasoline.
3 Put cap on the container, and
close tightly.
4 Shake the container to mix engine
oil and gasoline well and even.
5 Pour the mixture into fuel tank.
Notes
● It is recommended to pre-mix
by using separate fuel container.
Attempting to pre-mix in the fuel
tank built-in the boat can make the
mixture uneven.
● If built-in fuel tank is used for
mixing, pour engine oil into the tank
little by little while putting gasoline
into the tank.
PRE-OPERATING PREPARATIONS 25
3. Break-in
Your new outboard motor and lower
unit require break-in for the moving
components according to the
conditions described in the following
time table.
● Break-in period: 10 hours.
Throttle Position
Speed
�������
!
Operating the outboard motor without
break-in can shorten service life of the
product.
If any abnormality is experienced
during the break-in:
• Discontinue the operation
immediately.
• Have the dealer check the product
and take proper action(s) if
necessary.
1-10min
10min-2hrs
2-3hrs
3-10hrs
After 10hrs
Idle
Less than 1/2
throttle
Less than 3/4
throttle
3/4 throttle
Full throttle
available
Approx.
4,000 rpm.
Full throttle run
Approx.
allowed for 1 min Full throttle run
3,000 rpm max
every 10 min allowed for 2 min
every 10 min
Note
Proper break-in allows outboard motor
to deliver it full performance for longer
service life.
Fuel mix ratio for break-in
Gasline 25: Genuine Engine Oil 1
● 25:1 when using genuine engine oil
or the recommended one (TCW3).
!
������
Do not operate the outboard motor
in closed area or area with no forced
ventilation.
Exhaust gas emitted by this outboard
motor contains carbon monoxide
that will cause death if inhaled
continuously. Inhaling the gas initially
causes symptoms such as feeling of
sickness, drowsiness and headache.
During operation of the outboard
motor :
• Keep peripheral area well ventilated.
• Always attempt to stay on the
windward side of emission.
4
26
ENGINE OPERATION
1. Starting
!
1 Loosen the air vent screw on the
tank cap.
�������
Air Vent Screw
In case engine starts in gear, do not
start cruising. Stop engine immediately
and consult an authorized dealer.
Note
The engine will not start unless
the switch lock has been properly
connected into the emergency stop
switch.
5
!
�������
Do not operate the engine with gear
case out of water.
Severe personal injury, or engine
damage will result.
2 Attach the fuel connector to the
engine connector.
The arrow mark on the primer bulb
should be facing the engine.
3 Feed fuel to the carburetor by
squeezing the primer bulb until it is
firm.
Arrow mark
to Engine
to Fuel tank side
Primer bulb
ENGINE OPERATION 27
MF and EF type
4 Place the shift lever in the Neutral
position.
Be sure that the shift is in Neutral
when starting the engine.
6 Pull out the choke knob all the way.
(No choke operation is necessary
when the engine is warm.)
This model is provided with start in
gear protection.
(N)
MF type
!
�������
7 Pull the starter handle slowly until
you feel resistance. Then pull it
quickly.
If the engine starts in gear, do not use
it. Contact an authorized dealer.
Slowly
Quickly
Note
Start-in-gear protection prevents
engine from starting at other than
neutral shift. In-gear starting of engine
will move the boat immediately,
potentially leading to falling down or
causing passenger(s) to be thrown
overboard.
EF type
5 Turn the throttle grip until the mark
on the grip faces the triagular mark
on the steering handle.
7 Push the starter button.
8 Release pushing the button when
the engine has started.
5
28 ENGINE OPERATION
Note
If use the choke knob for the engine
start, push back it when the engine
has started.
8 Stop pushing the key when the
engine has started.
The key returns to the original
position, automatically.
9 Returns the Free accel lever to close
position.
EP type
4 Insert the main switch key.
5 Set the control lever in the Neutral
position.
Lock button
ON
OFF
Neutral (N)
5
Control
lever
Fully open
Push to
operate
choke
Fully closed
Free accel lever
Main switch
key
Stop
switch
Note
6 Raise the free accel lever a little (both
of cold engine and warm engine).
7 Turn the main switch key to START
position. Then, continuously push
the key to operate the choke.
Note
Choke operation is not necessary if the
engine is warm.
The free accel lever cannot raise when
the control lever shift is in Forward or
Reverse.
!
�������
Do not keep turning starter motor for
over 3 seconds, or the battery may
be consumed, potentially making the
engine starting impossible and/or
damaging the starter.
If cranking over 3 seconds fails to
start engine, return main switch to
"ON", and crank engine again after 5
seconds or more.
ENGINE OPERATION 29
If the recoil starter fails to operate
• Remove the top cowl and the recoil
starter. Wrap a rope around the
starter pulley then pull quickly to
start.
• Use a 10 mm socket wrench as a
rope handle.
Hook lever
!
�������
Be careful that your clothes or other
items do not get caught in the rotating
engine parts.
To prevent accident and injury, do not
re-attach the recoil starter after the
engine has been started using the
emergency starter rope. Be sure to put
the top cowl back on.
Immediately contact an authorized
dealer when reaching shore.
!
�������
• Be sure that no bystander(s) is
within 2 meters from back of
starting operator.
• Do not operate the outboard motor
with top cowl removed from the
power unit, or contacting turning
flywheel which can lead to serious
personal injury.
Starter lock rod
5
30 ENGINE OPERATION
2. Warming up the engine
Engine speed
Idling speed after warming up.
Warm the engine at low engine speeds
for about three minutes. This allows the
lubricating oil to circulate to all parts
of the engine. Operating the engine
without warm up shortens the engine's
life.
Be sure to check that cooling water is
coming out of the cooling water check
port during warm up.
!
5
�������
If the engine is operated without water
discharging from the check port or idle
port, the engine may over heat.
!
�������
Be sure to stop engine immediately
if cooling water check port is not
discharging water, and check if cooling
water intake is blocked. Operating
engine could lead to overheating
potentially leading to engine damage.
Consult an authorized dealer if the
cause cannot be found.
Idle port
Cooling
water
check port
Remark: In case of cold engine starting,
idling speed is increased about 300
rpm for several minutes.
Clutch in (In gear)
Clutch off (Out of gear)
750 rpm
900 rpm
Propeller selection
Propeller must be selected that
will allow the engine to reach
recommended rpm when cruising at
wide-open throttle.
Model
Wide-open throttle rpm range
6B • 8B
4,500 – 5,500 rpm
9.8B
5,000 – 6,000 rpm
Genuine propellers are listed on
PROPELLER TABLE of this manual.
ENGINE OPERATION 31
3. Forward and reverse
!
�������
Before shifting into forward or reverse,
make sure that boat is properly
moored and outboard motor can be
steered fully to the right and left. Make
sure that no swimmer(s) is ahead or
astern of the boat.
!
MF and EF type
(N)
(R)
(F)
�������
• Attach other end of emergency
stop switch tether to the operator's
clothing or arm and keep it
attached during cruising.
• Do not attach the tether to a part
of clothing that can be torn easily
when pulled.
• Arrange the tether so that will not be
caught by any object when pulled.
• Be careful not to pull the tether
accidentally during cruising.
Unintentional stop of engine can
cause loss of control of outboard
motor. Rapid loss of engine
power can lead to falling down or
causing passenger(s) to be thrown
overboard.
Note
Do not increase engine speed
unnecessarily in reverse.
!
�������
Severe damage, and personal injury,
may occur if shifting at high engine
speed.
Engine must be in the slow idle
position before shifting is attempted.
■ Forward
Turn the throttle grip to reduce engine
speed. When the engine reaches
trolling (or idling) speed, quickly pull the
shift lever to the Forward position.
■ Reverse
Reduce engine speed, when the engine
reaches trolling (or idling) speed, quickly
push the shift lever to the Reverse
position.
!
�������
Before shifting, make sure that no
swimmer(s) or obstacle(s) is ahead or
astern of the boat.
5
32 ENGINE OPERATION
EP type
Control lever
Be sure to warm up engine well before
starting cruise. Operating cold engine
may cause damage to your motor.
Lock button
e
Fully
open
e
ttl
tle
ut
abo °
32
Re
t ( verse
R)
abou
32° t
ro
rot
Neutral
(N)
Shif
Th
Th
t
Shif
los
5
d
ar
rw
Fo (F)
ly c
Ful
Idle speed may be higher during
warming up of engine. If shifted to
Forward or Reverse during warming
up, it may be difficult to shift back to
neutral. In such case, stop engine, shift
to neutral, and restart engine to warm
up.
los
e
Note
ly c
�������
Ful
!
lly
Fu en
op
Free
accel
lever
Note
Frequent shifting to forward or reverse
can accelerate wear or degradation of
parts. In such case, replace gear oil
earlier than the period specified.
■ Forward
Quickly push the control lever to the
Forward (F) position 32˚, where the
gear is connected, while lifting up on
the lock button located at the bottom
of the control lever grip. Further shifting
will open the throttle.
■ Reverse
Quickly pull the control lever to the
Reverse (R) position at 32˚, where the
gear is connected, while lifting up on
the lock button located at the bottom
of the control lever grip. Further shifting
will open the throttle.
ENGINE OPERATION 33
Note
The control lever is inoperative unless
the free accel lever is in the fully closed
position.
4. Stopping
MF and EF type
Stop switch
Note
Reduce the engine speed when
the control lever is in Neutral and
do not increase the engine speed
unnecessarily.
Stop switch
lock
Hook
1 Turn the throttle grip to the slow
position.
2 Put the shift lever in the Neutral
position.
Run the engine for 2-3 minutes at
idling speed if it has been running at
full speed.
3 Push the stop switch to stop the
engine or release the stop switch
lock.
!
�������
• Do not shift into Reverse during
planing, or control will be lost
leading to serious personal injury,
boat may swamp, and/or hull may
be damaged.
• Do not shift into Reverse during
cruising, or control may be
lost, falling down or causing
passenger(s) to be thrown
overboard. Leading to serious
personal injury, and steering
system and/or shifting mechanism
may be damaged.
5
34 ENGINE OPERATION
EP type
5. Trim angle
OFF
ON
Stop
switch
lock
(N)
The trim angle of the outboard motor
can be adjusted to suit the transom
angle of the hull, and load conditions.
Choose an appropriate trim angle that
will allow the anti ventilation plate to
run parallel to the water surface during
operation.
■ Proper trim angle
The position of the thrust rod is correct
if the hull is horizontal during operation.
Perpendicular to the
water surface
5
1 Put the shift lever in the Neutral
position and run the engine for 2-3
minutes at idling speed if it has been
running at full speed.
2 Turn the main switch key to the OFF
position.
Notes
• After stopping the engine, close the
air vent screw on the tank cap.
• Disconnect the fuel connector of
the engine or the fuel tank.
• Disconnect the battery cable of the
EF or EP type engine, if the engine
will not be used for more than 3
days.
■ Improper trim angle
Set the thrust rod lower if the bow of
the boat rises above horizontal.
■ Improper trim angle
Set the thrust rod higher if the bow of
the boat is below horizontal.
ENGINE OPERATION 35
6. Tilt up, tilt down and shallow water operation
!
Thrust rod
Higher
�������
When tilting up or down, be careful not
to place your hand between the swivel
bracket and the stern bracket.
Be sure to tilt the outboard motor
down slowly.
Lower
Note
!
�������
• Do not put hand or finger in
between outboard motor body and
clamp bracket when adjusting trim
angle to prevent injury in case the
outboard motor body falls.
• Unsuitable trim position can cause
loss of control of boat.
When testing a trim position, run
boat slow initially to see if it can be
controlled safely.
!
Stop the engine before tilting up.
■ Tilt up
With the shift lever in Neutral or
Forward, fully tilt the outboard motor
up toward you by holding the tilt handle
provided at the rear of the top cowl.
Then lower the tilt lever for locking at
tilt-up position.
�������
Excessive trim up or down may lead
to unstable boat operation, potentially
causing the steering difficulty that
leads to accident during cruising.
• Do not cruise at high speed if
improper trim position is suspected.
Stop the boat and readjust trim
angle before continuing cruise.
Neutral (N)
5
36 ENGINE OPERATION
Tilt Lever
■ Tilt down
Slightly tilt the outboard motor up, and
pull the tilt lever toward you to release
the tilt-lock. Then lower the outboard
motor slowly.
Tilt up position
Shallow water
operating position
5
!
�������
• Do not put hand or finger in
between outboard motor body and
clamp bracket when adjusting trim
angle to prevent injury in case the
outboard motor body falls.
• When tilting up outboard motor with
fuel joint for over a few minutes,
be sure to disconnect fuel hose or
close fuel cock, or fuel may leak,
potentially catching fire.
!
�������
Do not tilt up outboard motor during
operation, or engine may be damaged
from overheating due to lack of
sufficient cooling water.
■
Shallow water operation
!
�������
During shallow water operation, be
careful not to place your hand between
the swivel bracket and the stern bracket.
Be sure to tilt the outboard motor down
slowly.
Note
Slow down to trolling speed, and shift
into Neutral before setting outboard
motor to shallow water drive position.
ENGINE OPERATION 37
!
�������
• Run at lowest possible speed when
using shallow water drive.
• Tilt lock is disabled when in shallow
water drive position.
• When driving shallow water, be
careful not to strike outboard motor
against sea bottom, or propeller
may be pushed out of water,
resulting in loss of control.
1 Shallow water running position:
With the shift lever in Neutral or
Forward, tilt the outboard motor up
slowly by about 40˚ and then lower
the tilt lever for setting at the shallow
water running position.
Tilt lever
!
�������
While in shallow water drive position,
do not operate the outboard motor in
reverse. Operate the outboard motor
at slow speed and keep the cooling
water intake submerged.
!
�������
Do not tilt up or down outboard motor
when swimmer(s) or passenger is near
to prevent them from being caught
between outboard motor body and
clamp bracket in case the outboard
motor body falls.
5
!
�������
When tilting up outboard motor with
fuel joint for over a few minutes, be
sure to disconnect fuel hose or close
fuel cock, or fuel may leak, potentially
catching fire.
!
Shallow water
running position
2 Return to normal running position:
Tilt the outboard motor up fully and
then return the outboard motor
down slowly to the normal running
position.
�������
Do not tilt up outboard motor while
engine operates, or no cooling water
may be fed, leading to engine seizure
due to overheating.
38
REMOVING AND CARRYING THE OUTBOARD MOTOR
1. Removing the outboard motor
3. Storing the outboard motor
1 Stop the engine.
2 Disconnect the fuel connector,
the remote control cables and the
battery cords from the outboard
motor.
3 Remove the outboard motor from
boat and completely drain the water
from the gear case.
Outboard motor should be stored in a
vertical position.
!
�������
Engine may be hot immediately after
operating and could cause burns
if touched. Allow Engine to cool
down before attempting to carry the
outboard.
Note
If the outboard motor must be laid
down be sure the tiller handle faces
down as shown in the drawing above.
Elevate power unit 2 inches to 4 inches
if traveling to avoid oil spillage.
Propeller
6
Power head
Handle
2. Carrying the outboard motor
Keep the outboard motor in a vertical
position when carrying.
!
�������
Close air vent screw of fuel tank and
fuel cock before carrying or storing
outboard motor and fuel tank, or fuel
may leak, potentially catching fire.
!
�������
Do not carry or store outboard motor
in any of positions described below.
Otherwise, engine damage or property
damage could result from leaking oil.
39
TRAILERING
!
�������
Do not go under outboard motor tilted
up even if it is supported by support
bar, or accidental fall of outboard motor
could lead to severe personal injury.
!
�������
Close air vent screw of fuel tank and
fuel cock before carrying or storing
outboard motor and fuel tank, or fuel
may leak, potentially catching fire.
!
!
�������
When trailering the outboard motor
should be in a vertical (normal running)
position, fully down. Trailering in the
tilted position may cause damage to
the outboard motor, boat, etc.
If trailering with outboard motor fully
down is not available (the gear case
skeg is too close to the road in a
vertical position), fix the outboard
motor securely using a device (like a
transom saver bar) in the tilted position.
�������
When taking outboad motor from
package or removing outboad motor from
the boat, never release the lock lever. If
the lock lever is released, it will very easy
for the clamp bracket to spring up to the
tilting direction because it is not fixed.
*Care must be taken so as not to
release lock lever by accident.
*For more safety, tie the clamp bracket
to the outboard motor with a rope.
*Pay attention to the tilting direction so
as not to be injured by the springing
stern bracket.
!
�������
The tilt support device supplied on your
outboard motor is not intended for towing.
It is intended to support the outboard motor
while the boat is docked, beached, etc.
7
!
�������
Please disconnect fuel connector
except when operating engine.
Fuel leakage is a fire or explosion hazard,
which can cause serious injury or death.
40
ADJUSTMENT
1. Steering friction
The steering friction can be adjusted
in accordance with your preference by
turning the steering adjusting bolt.
Steering
adjusting bolt
2. Remote control lever load
(Throttle friction adjustment screw)
To adjust the load of the remote
control lever, turn the throttle friction
adjustment screw on the front of
the remote control. Turn clockwise
to increase the load and counterclockwise to decrease it.
Lighter
Lighter
Heavier
Heavier
Throttle friction
adjustment screw
Note
8
The steering adjust bolt is used to adjust
the sliding load of the steering, but not
to fix the steering. If excess tightning
given to the bolt may lead a cause of
damage to the swivel bracket.
!
�������
3. Throttle grip
The turning force of the throttle grip
can be adjusted with a throttle adjust
screw.
Do not overtighten the throttle grip or
remote control tensioner or it could
result in difficulty of movement resulting
in the loss of control causing an
accident and could lead to severe injury.
Lighter
Heavier
Throttle
adjustment
screw
ADJUSTMENT 41
4. Trim tab adjustment
If straight-line cruising can not be
achieved, adjust the trim tab located
under the anti-ventilation plate.
• If the boat veers toward the right,
direct the trim tab towards A.
• If the boat veers toward the left,
direct the trim tab towards B.
B
A
Trim tab
Notes
• The trim tab also acts as an anode
to prevent electrolytic corrosion.
Therefore do not paint or grease
this part.
• After adjustment securely tighten
the trim tab fixing bolt.
• Check for looseness of the bolt and
the trim tab at regular intervals.
Note
Due to corrosion, the trim tab will wear
down over time.
The trim tab should be replaced when
it has eroded 2/3 of it's regular size.
!
�������
• Inappropriate adjustment of trim
tab could cause steering difficulty.
After installing or readjusting trim
tab, check if steering load is even.
• Tighten trim tab bolt to specified
torque.
!
�������
• Be sure that outboard motor is
secured to transom or service
stand, or accidental drop or fall
of outboard motor could lead to
severe personal injury.
• Be sure to lock outboard motor
if it is tilted up, or accidental fall
of outboard motor could lead to
severe personal injury.
• Do not go under outboard motor
tilted up and locked, or accidental
fall of outboard motor could lead to
severe personal injury.
8
42
INSPECTION AND MAINTENANCE
Care of your outboard motor
To keep your outboard motor in the
best operating condition, it is very
important that you perform daily and
periodic maintenance as suggested in
the maintenance schedules that follow.
!
9
�������
• Your personal safety and that of
your passengers depends on how
well you maintain your outboard
motor. Carefully observe all of
the inspection and maintenance
procedures described in this
section.
• The maintenance intervals shown in
the checklist apply to an outboard
motor in normal use. If you use
your outboard motor under severe
conditions such as frequent
full-throttle operation, frequent
operation in brackish water, or
for commercial use, maintenance
should be performed at shorter
intervals. If in doubt, consult your
dealer for advice.
• We strongly recommend that you
use only genuine replacement parts
on your outboard motor. Damage
to your outboard motor arising from
the use of other than genuine parts
is not covered under the warranty.
INSPECTION AND MAINTENANCE 43
1. Daily inspection
Perform the following checks before
and after use.
!
�������
Do not use outboard motor if any
abnormality is found during pre-operation
check or it could result in severe damage
to the motor or severe personal injury.
Item
Points to Check
Action
Fuel System
• Check the amount of fuel in the tank.
• Check for debris or water in the fuel filters.
• Check the rubber hoses for fuel leakage.
Replenish
Clean
Replace
Replace
Replenish or recharge
Electrical
Equipment
• Check that the main switch functions normally.
• Check that the battery electrolyte level and specific gravity
are normal.
• Check for loose connections on the battery terminal.
• Check that the stop switch functions normally and make
sure the lock plate is there.
• Check cords for loose connections and damage.
• Check the spark plugs for dirt, wear and carbon build-up.
• Check that the choke solenoid and valve for the carburetor
function normally.
• Check if the carburetor and magneto work normally when
turning the throttle grip, and check links for looseness.
Replace
Choke and
Throttle System
Recoil Starter
• Check the rope for wear and chafing.
• Check the ratchet engagement.
Replace
Correct or replace
• Check that clutch engages correctly when operating the
shift lever and remote control.
• Visually Check propeller for bent or damaged blades.
• Check the propeller nut is tightened and the split pin is
present.
Adjust
Clutch and
Propeller
System
Installation of
Motor
• Check all the bolts attaching the motor to the boat.
• Check the thrust rod installation.
Tighten
Cooling Water
• Check that cooling water is discharged from the cooling
water check port after the engine has started.
Tools and Spares
• Check that there are tools and spare parts for replacing
spark plugs, the propeller, etc.
• Check that you have the spare rope.
Steering Devices
• Check the operation of the steering handle and remote
control.
Other Parts
• Check if the anode and trim tab are securely installed.
• Check the anode and trim tab for corrosion and
deformation.
Retighten
Remedy or replace
Correct or replace
Clean or replace
Correct
Replace
Repair or Replace
9
44 INSPECTION AND MAINTENANCE
Washing outboard motor
If outboard motor is used in salt water,
brackish water or water with a high
acidic level, use fresh water to remove
salt, chemicals or mud from exterior
and cooling water passage after every
cruising or before storing outboard
motor for long time. Before flushing,
remove the propeller and the forward
thrust holder.
!
�������
Keep cooling water passage free of
clogs, or lack of cooling water flow
could lead to engine overheating,
potentially resulting in engine trouble.
Note
It is recommended to check chemical
properties of water on which your
outboard motor is regularly used.
!
9
■ Use flushing plug.
1 Remove propeller (refer to Propeller
Replacement). Remove the water
plug from the motor, and screw in
the flushing plug.
2 Attach a water hose to the flushing
plug. Turn on the water and adjust
the flow. (Be sure to seal the water
inlet, located in the gear case, with
tape.)
3 Start the engine and run it at idle
speed in neutral shift position.
4 Check for a steady stream of water
flowing out of the water pump
indicator hole. Continue flushing the
outboard motor for 3 to 5 minutes,
carefully monitoring water supply at
all times.
5 Stop the engine, turn off the water
supply, and remove the flushing plug
and tape. Reinstall the propeller.
Flushing
plug
�������
Do not start engine without removing
propeller, or accidentally turning
propeller could cause personal injury.
!
Water
strainer
�������
Never start or operate the engine
indoors or in any space which is not
well ventilated. Exhaust gas contains
carbon monoxide, a colorless and
odorless gas which can be fatal if
inhaled for any length of time.
!
�������
Keep engine at idle speed during flushing.
INSPECTION AND MAINTENANCE 45
Replacing the propeller
A worn-out or bent propeller will lower
the motor's performance, and cause
engine trouble.
Before removing the propeller, remove
the spark plug caps from the spark
plugs to protect against personal injury.
!
�������
Do not begin propeller removal and
installation procedure with spark
plug caps attached, shift in forward
or reverse, main switch at other than
"OFF", engine stop cord attached to
the switch, and starter key attached, or
engine could accidentally start leading
to serious personal injury. Disconnect
battery cable if possible.
1 Remove the split pin, propeller nut
and washer.
2 Remove the propeller and thrust
holder.
3 Apply genuine grease to the
propeller shaft before installing a
new propeller.
4 Install the thrust holder, propeller,
washer and propeller nut onto the
shaft.
5 Install a new split pin into the nut
hole and bend it.
Propeller shaft
Propeller
Nut
Split pin
Washer
!
Propeller
thrust holder
�������
Do not hold propeller with hand(s)
when loosening or tightening propeller
nut. Put a piece of wood block
between propeller blade and anti
ventilation plate to hold propeller.
!
�������
• Do not install propeller without
thrust holder, or propeller boss
could be damaged.
• Do not reuse split pin.
• After installing split pin, spread the
pin apart to prevent it from falling
out which could lead to the propeller
coming off during operation.
9
46 INSPECTION AND MAINTENANCE
Replacing the spark plugs
!
�������
• Do not reuse spark plug with damaged
insulation, or sparks can leak through
crack, potentially leading to electric
shock, explosion and/or fire.
• Do not touch spark plugs immediately
after stopping engine as they will be
hot and could cause severe burns if
touched. Allow motor to cool down
first.
If the spark plug(s) is fouled, has
carbon build up, or is worn, it should
be replaced.
When reusing spark plugs, remove dirt
from the electrodes and adjust spark
gap to specification.
Note
When inspecting the plug, always
clean the gasket surface and use a
new gasket. Wipe off any dirt from the
threads and screw in the spark plug to
the correct torque.
9
Stop the engine.
Remove the top cowl.
Remove the spark plug caps.
Remove the spark plugs by turning
it counter-clockwise, using a 21
mm (13/16 in) socket wrench and
handle.
5 Attach spark plug and tighten to
specified torque.
1
2
3
4
Use spark plugs (NGK B7HS-10 or
BR7HS-10) or recommended ones.
Electrode
Spark gap : 0.9 - 1.0mm
(0.035 - 0.039 in)
Note
• Spark plug torque :
25.0 Nm (18.1 ft-lb) (2.5 m-kg)
If a torque-wrench is not available
when you are fitting a spark plug, a
good estimate of the correct torque is
1/4 to 1/2 a turn past finger-tight. Have
the spark plug adjusted to the correct
torque as soon as possible with a
torque-wrench.
INSPECTION AND MAINTENANCE 47
Replacing the anode
A sacrificial anode protects the outboard
motor from galvanic corrosion. Anode is
located on the gear case, clamp bracket
and the cylinder. When the anode is
eroded more than 2/3, replace it.
Notes
• Never grease or paint the anode.
• At each inspection re-tighten the
anode attaching bolt. As it is likely
to be subjected to electrolytic
corrosion.
Anode
(Trim tab)
9
48 INSPECTION AND MAINTENANCE
2. Periodic inspection
It is important to inspect and maintain your outboard motor regularly. At each interval
on the chart below, be sure to perform the indicated servicing. Maintenance intervals
should be determined according to the number of hours or number of months,
whichever comes first.
Servicing Interval
Item
10 hours
or
1 month
50 hours
or
3 months
*Carburetor
Fuel
System
Ignition
9
Lower
Unit
●
Strip, clean and adjust.
Adjust idling.
Fuel filter
●
●
●
Check and clean.
Piping
●
●
●
Check and Replace.
Fuel tank
●
●
Clean.
Spark
plugs
●
●
Check gaps.
Remove carbon
deposits or Replace.
*Ignition
timing
●
●
Adjust timing.
●
Check for salt deposits and
battery cable condition.
*Starter
motor
Starting
System
Action
Every 100
hours or 6
months
Battery
●
●
●
Check Installation, fluid
quantity, gravity.
Starter rope
●
●
●
Check for wear or damage.
Propeller
●
●
●
Check for bend blades,
damage, wear.
Gear oil
●
●
●
Change or replenish-oil and
check for water leaks.
●
●
Check for wear or damage.
●
●
Retighten.
●
●
Apply and pump in grease.
●
●
Check for corrosion.
●
Check for corrosion and
deformation.
*Water pump
Bolt and Nuts
●
Sliding and Rotating Parts.
Grease Nipples
Outer Equipment
Anode
*Have this handled by your dealer.
●
●
Remarks
Replace impeller
every 12 months.
Replace.
INSPECTION AND MAINTENANCE 49
Note
Also, your outboard motor should
receive careful, and complete,
inspection at 300 hours. This is the
best time for major maintenance
procedures to be carried out.
■ Fuel filter (for engine)
Remove the cap, then clean the fuel
filter in the engine.
Fuel pump
Cleaning the fuel filters and the
fuel tank
Fuel filters are provided inside the fuel
tank and engine.
!
�������
Gasoline and its vapors are very
flammable and can be explosive.
• Do not start this procedure while
engine is operating or hot even
after stopping it.
• Place fuel filter away from every
source of ignition such as sparks or
open flames.
• Wipe off gasoline well immediately
if spilled.
• Install fuel filter with all related parts
in place, or fuel leak could occur,
leading to catching fire or explosion.
• Check fuel system regularly for
leakage.
• Contact authorized dealer for
fuel system services. Services by
unqualified person could lead to
engine damage.
Fuel pipe
Fuel filter
■ Fuel filter (for fuel tank)
Remove the fuel pickup elbow of the
fuel tank by turning it counterclockwise
and clean the fuel filter.
■ Fuel tank
Water or dirt in the fuel tank will cause
engine performance problems.
Check and clean the tank at specified
times or after the outboard motor has
been stored for a long period of time
(over three months).
Fuel pick up elbow
Fuel
pick up
elbow
Filter
9
50 INSPECTION AND MAINTENANCE
Replacing gear oil
!
�������
• Be sure that outboard motor is
secured to transom or service
stand, or accidental drop or fall
of outboard motor could lead to
severe personal injury.
• Be sure to lock outboard motor
if it is tilted up, or accidental fall
of outboard motor could lead to
severe personal injury.
• Do not go under outboard motor
tilted up and locked, or accidental
fall of outboard motor could lead to
severe personal injury.
1 Remove the oil plugs (upper and
lower), and completely drain the
gear oil into a pan.
Oil plug
(upper)
9
Oil plug
(lower)
2 Insert the oil tube nozzle into the
lower oil plug hole, and fill with gear
oil by squeezing the oil tube until oil
flows out of the upper plug hole.
!
�������
Do not reuse oil plug gasket. Always
use new gasket and tighten oil plug
properly to prevent entry of water into
lower unit.
Oil plug
(upper)
INSPECTION AND MAINTENANCE 51
3 Install the upper oil plug, and then
remove oil tube nozzle and install
the lower oil plug.
Oil plug
(upper)
3. Off-season storage
Before you put your outboard motor
in storage, it is a good opportunity to
have it serviced and prepared by your
dealer.
!
Oil plug
(lower)
�������
Before servicing the motor for storage:
• Remove the battery cables.
• Remove the spark plug caps from
the spark plugs.
• Do not run the motor out of the water.
Engine
Note
If water in the oil, giving it a milky colored
appearance. Contact your dealer.
Note
Use genuine gear oil or the
recommended one (API GL-5: SAE
#80 to #90).
Required volume
: approx. 320 mL (0.08 U.S. gal.)
1 Wash the engine exterior and flush
the cooling water system thoroughly
with fresh water. Drain the water
completely.
Wipe off any surface water with an
oily rag.
2 Use a dry cloth to completely wipe
off water and salt from the electrical
components.
3 Drain all fuel from the fuel hoses,
fuel pump, and carburetor, and
clean these parts.
Keep in mind that if gasoline is
kept in the carburetor for a long
time, gum and varnish will develop,
causing the float valve to stick,
restricting the fuel flow.
4 Remove the spark plugs and feed
genuine engine oil or storage
fogging oil in through the spark plug
holes.
The oil will be fed into the crank
case from the air silencer attached
9
52 INSPECTION AND MAINTENANCE
5
6
7
8
to the carburetors. Turn the engine
over several times while feeding the
oil into it and make sure it is evenly
distributed.
Change the gear oil in the gear
case.
Apply grease to the propeller shaft.
Apply grease to all sliding parts,
joints, nuts, and bolts.
St a n d t h e o u t b o a r d m o t o r u p
vertically in a dry place.
!
�������
Be sure to use cloth to remove fuel
remaining in the cowl and dispose of it
in accordance with local fire prevention
and environment protection regulations.
Battery
9
1 Disconnect the battery cables.
2 Wipe off any chemical deposits, dirt,
or grease.
3 Apply grease to the battery
terminals.
4 Charge the battery completely
before storing it for the winter.
5 Recharge the battery once a month
to prevent it from discharging and
the electrolyte from deteriorating.
6 Store the battery in a dry place.
Electric Starter Motor
Coat the internal pinion gears and the
shaft of the electric starter motor with
grease.
Do not put grease on the teeth of the
starter pinion or flywheel or increased
wear or damage will occur.
INSPECTION AND MAINTENANCE 53
4. Pre-season check
1 Check that the shift and throttle
function properly.
(Be sure to turn the propeller shaft
when checking the shift function or else
the shift linkage may be damaged.)
Notes
The following steps must be taken
when first using the engine after winter
storage.
1 Warm up the engine for 3 minutes
in the "NEUTRAL" position.
2 Run the engine for 5 minutes at the
slowest speed.
3 Run the engine for 10 minutes at
half speed.
In Steps 2 and 3 above, the oil
used for storage inside the engine
will be flushed out to assure optimum
performance.
Specific
Gravity at 20 °C
Terminal
Voltage (V)
Charge
Condition
1.120
10.5
Fully
discharged
1.160
11.1
1/4 charged
1.210
11.7
1/2 charged
1.250
12.0
3/4 charged
1.280
13.2
Fully charged
3 Check that the battery is secure
and the battery cables are properly
installed.
2 Check the electrolyte level, and
measure the voltage and specific
gravity of the battery.
9
54 INSPECTION AND MAINTENANCE
5. Motor submerged in water
6. Cold weather precautions
After taking your outboard motor out of
the water, immediately take it to your
dealer.
The following are the emergency
measures to be taken for a submerged
outboard motor, if you can not take it
your dealer right away.
1 Wash the outboard motor with fresh
water to remove salt or dirt.
2 Remove the spark plugs, and
completely drain the water from the
engine by pulling the recoil starter
several times.
3 Inject a sufficient amount of genuine
engine oil through the spark plug
hole and into the crank case from
the carburetor side. Pull the recoil
starter several times to circulate the
oil throughout the outboard motor.
If you moor your boat in cold weather
at temperatures below 0˚C (32˚F), there
is the danger of water freezing in the
cooling water pump, which may damage
the pump, impeller, etc. To avoid this
problem, submerge the lower half of the
outboard motor into the water, or tilt the
motor up above water level and pull the
recoil starter several times to drain the
water completely.
!
9
�������
Do not attempt to start submerged
outboard motor immediately after it is
recovered, or engine could be severely
damaged.
INSPECTION AND MAINTENANCE 55
7. Checking after striking underwater object
Striking the sea bottom or an underwater
object may severely damage the
outboard motor. Immediately bring the
outboard motor to the dealer and ask for
the following checks.
1 Looseness or damage of power
unit installation bolts, gear case and
extension case bolts, propeller shaft
housing bolts, propeller or propeller
shaft upper and lower mount rubber
bolts, and/or mount bracket bolts.
Ask an authorized dealer to tighten
any loose bolts and nuts, and to
replace damaged parts.
2 Damage to mount rubber, the tilt
stopper, thrust rod, gears and
clutch, and/or propeller.
Ask an authorized dealer to replace
damaged or defective parts.
9
56
TROUBLESHOOTING
High engine speeds not possible
●
●
●
●
●
Incorrect connection of fuel sysytem
●
●
●
●
●
●
●
Air entering fuel line
●
●
●
●
●
●
●
Deformed or damaged fuel pipe
●
●
●
●
●
●
●
Closed air vent on fuel tank
●
●
●
●
●
●
●
Clogged fuel filter, fuel pump, or carburetor
●
●
●
●
●
Use of improper engine oil
●
●
●
●
Use of improper gasoline
●
●
●
●
●
Overheating of engine
●
Engine speed abnormally low
●
Engine speed abnormally high
●
Poor acceleration
Engine starting but stoping soon
●
Poor idling
Engine failing to start
FUEL SYSTEMS
If you encounter a problem, consult the check list below to determine the cause and
to take the proper action.
An authorized dealer will always be happy to provide any assistance and information.
Empty fuel tank
●
Excessive oil in mixture
●
●
●
ELECTRIC SYSTEMS
10
Shortage of oil in mixture
Excessive supply of fuel
●
●
●
Poor carburetor adjustment
●
●
Recirculation pipe broken
●
●
●
Spark plugs other than specified
●
●
●
Dirt, soot, etc. on spark plugs
●
●
●
No spark or weak spark
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Short circuit of engine stop switch
●
●
Possible cause
●
●
●
●
Incorrect adjustment of ignition timing
ELECTRIC SYSTEMS
Overheating of engine
High engine speeds not possible
Engine speed abnormally low
Engine speed abnormally high
Poor acceleration
Poor idling
Engine starting but stoping soon
Engine failing to start
TROUBLESHOOTING 57
Possible cause
●
Loose battery terminal connection, corrosion
●
Discharged battery
●
Main switch trouble
●
Lock plate not fitted to stop switch
●
Disconnection of wire or loose ground connection
●
Insufficient battery capacity, loose terminal
connection, corrosion
●
●
●
●
OTHERS
●
●
EP and EF
types
EP and EF
types
Incorrect adjustment of throttle link
●
●
●
Insufficient cooling water flow, clogged or defective pump
●
●
Faulty thermostat
●
●
Cavitation or ventilation
●
●
●
●
●
●
●
Incorrect propeller selecition
●
●
●
●
●
Damaged and bent propeller
●
●
●
●
Improper thrust rod position
●
●
●
●
●
Unbalanced load on boat
●
●
●
●
●
Transom too high or too low
10
58 TOOL KIT AND SPARE PARTS
TOOL KIT AND SPARE PARTS
The following a list of the tools and spare parts provided with the motor.
Items
Service Tools
Spare Parts
Parts
Packaged with
Engine *
Tool Bag
Pliers
Socket Wrench
Socket Wrench
Socket Wrench Handle
Screwdrivers
Screwdriver handle
1
1
1
1
1
1
1
Rope
Spark Plug
Split Pin
1
1
1
Fuel Tank
Primer bulb
1
1 set
Remote Control
Remote Control Attachment
1 set
1 set
* Not provided with the motor in some markets.
11
Quantity
Remark
10 X 13 mm
21mm
Cross- and straight-point
1,000 mm
NGK B7HS-10 or BPR7HS-10
EP only
EP only
OPTIONAL ACCESSORIES 59
OPTIONAL ACCESSORIES
Alternator (12V, 80W)
(for lamp in run mode only)
Extension cord for light
(Lights are available on the market.)
Tachometer
Genuine grease (250g)
Genuine gear oil (500mL)
Flushing plug
Genuine Engine Oil (0.4L, 1L, 4L, 20L)
Touch-up Paint
Vertical
starter
Rectifier (for charging battery 12V)
Alternator
12
Battery or lamp
60
PROPELLER TABLE
Use a genuine propeller.
A propeller must be selected so that the engine rpm measured at wide open throttle
while cruising is within the recommended range.
Recommended range at WOT: 6B • 8B = 4,500 to 5,500 rpm
9.8B
= 5,000 to 6,000 rpm
Mark
Light boats
Heavy boats
inch
mm
9.5
8.9 x 10
226 x 255
F8.5
8.9 x 8.3
226 x 211
7.5
8.5 x 7.5
216 x 190
7
8.9 x 7.0
226 x 178
6.5
8.5 x 6.5
216 x 165
S : Short shaft
L : Long shaft
UL : Extra long shaft
13
Propeller Size
(Diameter x pitch)
Standard propeller on the model
6
8
9.8
S
S
S
L
L & UL
L & UL
MEMO
MEMO
OWNER’S
MANUAL
M 6B
8B
9.8B
OWNER’S MANUAL
M 6B
8B
9.8B
M6-8-9.8_E_cover_110113.indd 1
TOHATSU CORPORATION
Address : 5-4, 3-chome, Azusawa, Itabashi-ku,
TOKYO, 174-0051 JAPAN
Phone : TOKYO (03)3966-3117
FAX :
TOKYO (03)3966-2951
Website : www.tohatsu.co.jp
OB No.003-11029-D
003-11029-B 1101NB
Printed in Japan
11.1.13 11:29:32 AM
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